Apparatus and method for filling flexible containers

ABSTRACT

This disclosure relates to the filling of flexible containers with compacted finely divided materials utilizing a filler of the pressure differential type. During the filling of the container, the container is pneumatically supported to establish and maintain a predetermined shape and volume whereby finely divided material of a constant density may be compactly placed therein to obtain a filled container having therein a predetermined weight of the material without weighing the material. Another feature of the apparatus is that in the absence of a container, although a filler may be actuated to dispense material, no dispensing will take place. A further feature is the relationship of the filler to a carton having upstanding flaps and a liner wherein the carton may be filled to overflowing, but wherein the material in the carton has a recess due to the shape of the filler, and wherein in the normal closing of the carton, the overflowing material may be automatically displaced into the recess to provide for a completely filled carton.

Unite States Patent {72] lnventor Clarence W. Vogt Box 232, Westport, Conn. 06880 {21] App1.No. 748,087

122] Filed July 26. 1968 [45] Patented Aug.3,1971

[54] APPARATUS AND METHOD lFOlR lFlLLllNG FLEXllBLE CONTAINERS 5 Claims, 12 Drawing Figs.

[52] 11.5. CI 53/67, 53/76, 53/266, 53/381, 269/21 [51] Int. Cl ..lB65lb 57/06,

B656 3/14, B65b 1/28 [50] Field of Search 53/266, 67, 76, 381; 269/21 [56] References Cited UNITED STATES PATENTS 3,514,919 6/1970 Ashton 53/266 X 1,390,627 9/1921 Lindahl 269/21 1,616,188 2/1927 Hatchet 269/21 X 2,113,636 4/1938 Vogt 53/112 A 2,177,919 10/1939 Vogt... 53/266 X 2,750,721 6/1956 Earp... 53/67 2,976,654 3/1961 Vogt... 53/266 X 3,103,089 9/1963 Allen 269/21 X 3,124,916 3/1964 Anderson 53/381 X Primary Examiner-Wayne A. Morse, .llr. Attorney-Diner, Brown, Ramik and Holt ABSTRMIT: This disclosure relates to the filling of flexible containers with compacted finely divided materials utilizing a filler of the pressure differential type. During the filling of the container, the container is pneumatically supported to establish and maintain a predetermined shape and volume whereby finely divided material of a constant density may be compactly placed therein to obtain a filled container having therein a predetermined weight of the material without weighing the material. Another feature of the apparatus is that in the absence of a container, although a filler may be actuated to dispense material, no dispensing will take place. A further feature is the relationship of the filler to a carton having upstanding flaps and a liner wherein the carton may be filled to overflowing, but wherein the material in the carton has a recess due to the shape of the filler, and wherein in the normal closing of the carton, the overflowing material may be automatically displaced into the recess to provide for a completely filled carton.

PATENTED AUG 3 IBYI SHEU 1 OF .3

INVENTOR CLARENCE ULVOGFY PM /xms PATENTEU M; 319?:

SHEET 2 OF 3 INVENT OR CLARNCE mvoen ATTORNEYJ PATENTEU Am; 3 I97! SHEET 3 BF 3 INVENTOR CLHRENCE U). \IOGT ATTOR NEYS APPARATUS AND METHOD FOIR FILLING FLEXIBLE CONTAINERS This invention relates in general to new and useful improve ments in apparatus for filling containers with a finely divided material, and more particularly to a filling apparatus for compactly filling flexible containers utilizing a filler of a differential pressure type.

I have found that when provided with containers of uniform volumes, I can compactly fill such containers with a finely divided material to such uniform density that the variation in weights of the materials placed in the containers will be a minimum and within a percentage which is economically feasible. However, in the past difficulties have arisen with flexible cartons inasmuch as any flexing of the carton changes the volume thereof. On the other hand, most finely divided materials are dispensed in cartons. Therefore, in the past, it has been necessary to first fill a measuring cup and then transfer the material from the measuring cup into the flexible carton. However, in accordance with this invention, I am able to compactly fill flexible cartons with uniform weights of finely divided materials without weighing such materials.

Another feature of this invention is to provide a novel filling apparatus for filling flexible containers wherein the containers are pneumatically supported to establish and maintain a predetermined shape and volume during the filling thereof and wherein the so supported container may be filled with a filler of the pressure differential type so as to have the finely divided material compactly disposed therein to provide for a maximum material within a given volume.

Another feature of this invention is to provide an apparatus which is particularly adapted for filling flexible containers and wherein the apparatus is of a type which requires a container to be disposed in sealed relation with respect to the filler ofthe apparatus for the filler to function even though operation thereof is initiated whereby the apparatus is automatically of the no-container no-fill type.

A further feature of this invention is to provide a novel method of filling cartons having upstanding closure flaps and a lining, the method including the steps of compactly filling the carton to overflowing utilizing a filler of the pressure differential type and wherein a recess is formed in the upper portion of the filled material due to the shape of the filler, the overflowing material being automatically shifted into the recess in the material during the normal closing of the carton.

With the above and other objects in view that will hereinafter appear, the nature of the invention will be more clearly understood by reference to the following detailed description, the appended claims and the several views illus trated in the accompanying drawings:

In the drawings:

FIG. 1 is a vertical sectional view taken through a filling apparatus formed in accordance with this invention and shows generally the details thereof.

FIG. 2 is a horizontal sectional view taken along the line 2-2 of FIG. I and shows specifically the details of the shroud for the carton.

FIG. 3 is an enlarged fragmentary vertical sectional view showing that portion of the apparatus identified in FIG. 1 and more specifically discloses the manner in which a seal is formed between the carton and both the shroud and the filler.

FIG. 4 is an enlarged fragmentary sectional view showing in greater detail that portion of the shroud identified in FIG. 2.

FIG. 5 is a fragmentary vertical sectional view similar to FIG. I and shows a slightly modified form of filler.

FIG. 6 is a horizontal sectional view taken along the line 6-6 of FIG. 5 and shows further the details of the filler.

FIG. 7 is a perspective view of a carton for which the filling apparatus is particularly designed.

FIG. 8 is a sectional view through the upper portion of the carton of FIG. 7 and shows the same after the same has been initially filled to overflowing.

FIG. 9 is a sectional view similar to FIG. 8 showing an initial step in the normal closing of the carton wherein the overflowing material is automatically being repositioned.

FIG. 10 is a fragmentary sectional view showing the end flaps ofthe carton in their fully closed position.

FIG. 11 is a fragmentary sectional view showing the upper portion of the carton after the first side flap has been folded into position.

FIG. 12 is a fragmentary sectional view showing the carton in its fully closed position.

Referring now to the drawings in detail, it will be seen that there is illustrated in FIG. 7 a carton which is to be filled in accordance with this invention. The carton is generally identified by the numeral 15 and is considered as being a flexible carton inasmuch as it is formed primarily of paperboard. The carton will be supplied to the filling apparatus of this invention in the erected form shown in FIG. 7 and includes a body l6 and a bottom closure 17 which is formed ofa plurality of folded and bonded together flaps. The carton 15 is provided with the upper end thereof opened ready to receive a finely divided material. After the carton 15 is filled, the upper end thereofis closed by an upper closure which is formed ofa plurality of flaps.

The flaps which form the upper end closure of the carton 15 includes a pair of end flaps l8 and I9 and a pair of side flaps and 21. In the forming of the end closure, the end flaps 18 and 19 will be folded in first, after which the side flap 20 will be folded in followed finally by the folding in of the side flap 21. It is to be understood that the side flap 21 will be adhesive ly secured to the side flap 20 to form a complete seal.

It is also to be noted that the carton 15 is provided with an internal liner 22. The liner 22 projects up out of the body 16 higher than the side flap 20, but not as high as the end flaps 18 and 119 and the side flap 21. The liner 22 is provided with a side seam 23 which is generally aligned with the side flap 20 and is remote from any of the corners of the carton 15.

Reference is now made to FIGS. 1 through 4 wherein there is illustrated an apparatus particularly adapted for filling the carton 15. The apparatus is generally identified by the numeral 25 and basically includes a shroud, which is generally identified by the numeral 26, and a filler, which is identified by the numeral 27. The filler 27 is of the pressure differential type and therefore, it is necessary that the carton 15 be pneumatically supported by the shroud 26.

The filler 27 includes an upper magazine portion 28 which may be suitably supported in any desired manner. The upper magazine portion 28 includes an outer shell 29 which is sealed at the opposite ends thereof to an inner liner 30, the liner 30 being preferably formed of a porous material, such as a sintered metal or plastic. A fluid line 31 is connected to the outer shell 29 for supplying gases, preferably air, into the space between the shell 29 and the liner 30 and through the liner 30 during the normal operation of the filler 27.

The seal between the lower ends of the shell 29 and the liner 30 is effected by means of an annular support member 32. The support member 32 has mounted thereon for quick removal a depending housing 33. The housing 33 is secured in place on the support member 32 by means of a plurality of circumferentially spaced fasteners 34.

The housing 33 is configurated to include an outer wall 35 and an inner wall 36 which define therebetween a downwardly opening chamber 37. The inner wall 36 also defines a valve chamber 38.

The valve chamber 38 has positioned therein a conical valve member 40 which includes a radially outwardly extending upper mounting flange 41. When the housing 33 is secured to the supporting member 32, the flange 41 is clamped in position and sealed relative to the housing 33. The valve member 40 also includes a lower mounting flange 42 which is clamped into sealed engagement with a lower portion of the wall 36 by means ofa removable nutlike member 43 which is threadedly engaged with the wall 36.

It is to be noted that the valve member also has a transverse lower wall portion 44 which is generally coplanar with the flange 42. The lower wall 44, as is best illustrated in FIG. 2, is split so as to define a plurality of flaps 45. The flaps 45 have sufficient resiliency and stiffness to normally support a column of finely divided material disposed within the magazine 28, but are downwardly deflectable under a pressure differential to permit the rapid flow of finely divided material down through the valve member 40.

It is to be noted that the inner surface of the wall 36 is provided with an annular recess 46. A fluid passage 47 leads into the annular recess 46 and has coupled thereto a fluid line 48 through which a vacuum or positive pressure may be selectively applied. When a vacuum is applied through the fluid line 48, the valve 40 is pulled outwardly to its fully opened position. On the other hand, when a positive pressure is applied through the fluid line 48, the valve 40 is distorted to its phantom line position to form a primary seal above the flaps 45.

The space 37 has the lower end thereof closed by means of a filter 49 which is preferably of a saucer configuration to provide for a maximum area. The inner periphery of the filter 49 is secured to the wall 35 by the nutlike member 43 while the outer periphery of the filter is secured to the wall 35 by an adapter plate 50 which is suitably releasably secured to the lower end of the wall 35. If desired, the seal between the filter 49 and the wall 35 may be assured by means of a sealing ring 51.

Referring now to FIG. 2 in particular, it will be seen that while the valve member 40 and the nutlike member 43 are circular in section, the adapter ring 50 is rectangular in outline so as to be receivable within the carton 15. The filter 49 adapts from a circular outline to a rectangular outline.

The shroud 26 is formed in two halves 52 which are identical. The two halves 52 combine to define a pocket 53 of a size conforming to the external configuration of the carton 15. The vertical walls of the pocket 53 are principally defined by a screen 54 which is backed up by a plurality of vertically extending ribs 55. The ribs 55 provide for the free circulation of gases around the screen 54. In order that the desired pressure may be provided in the pocket 53, each of the shroud halves 52 includes a port 56 leading into the pocket 53 and a fluid line 57 coupled to the port 56. It is to be understood that a vacuum will normally be drawn through the passages 56.

The shroud 26 is seated on a plate 58which forms the bottom wall of the chamber 53. The plate 58 is illustrated as being flat, but that portion thereof which forms the bottom of the chamber 53 may be grooved and a vacuum line attached thereto so as to provide for the pneumatic supporting of the bottom of the carton as well as the body thereof.

In the illustrated form of shroud construction, the shroud is mounted for vertical movement while the filler 27 is stationary. Of course, the shroud 26 could be vertically fixed and the filler 27 may be vertically reciprocated. It is also to be noted that the shroud halves 52 are mounted for sliding movement away and towards one another. However, in a like manner, the shroud halves 52 could be pivotally connected together along one edge portion thereof. It is to be particularly noted that the parting line between the shroud halves 52 is coincidental with a diagonal of the carton.

Referring now to FIG. 3 in particular, it will be seen that the top portion of each of the shroud halves 52 is provided with an inwardly projecting sealing member 60 while the adapter ring 50 is provided with an outwardly projecting sealing member 61. The sealing member 60 provides a seal between the canon body 16 and the shroud 26 while the sealing member 61 provides a seal between the filler 27 and the carton liner 23. At this time, it is pointed out that the sealing members 60 and 61 are preferably hollow so as to have a maximum resiliency and thus provide an effective seal. It is also pointed out here that the sealing members 60 and 61 engage the carton body with the filler 27 projecting only slightly within the carton body. The position of the fold line 62 between the carton body 16 and the closure flaps is clearly illustrated.

It is to be understood that in the operation of the filler 27, a vacuum will normally be drawn within the chamber 37 through a fluid line 63 opening thereinto. The vacuum will be drawn through the filter 49 with the result that the vacuum will be drawn within the carton 15. In order to support the carton 15 against internal collapse due to this vacuum, the vacuum should be drawn within the shroud 26 at least as great as the vacuum drawn within the carton. It is to be understood that by drawing the vacuum within the shroud 26 around the carton 15, the carton 15 is pneumatically supported. In so supporting the carton, the carton is made to conform to the shape of the chamber 52 with the result that the configuration of the carton 15 is a predetermined one and the volume of the carton is determined and maintained.

It is to be understood that the filler 27 will function to remove a constant amount of entrapped gases from finely divided material handled thereby with the result that the finely divided material will be consistently placed within carton 15 at a known density. Since the volume of each carton 15 is predetermined and controlled, it will be seen that equal weights of a material may be placed within cartons without weighing the material in advance.

It is also pointed out at this time that when the valve member 40 is opened to its position of FIG. 1, the finely divided material disposed therein will rest upon the flaps 45. At this time no dispensing will take place. However, when the lower portion of the housing 33 is sealed by means of a carton 15 being sealed relative thereto, the vacuum drawn within the carton will result in the downward deflection of the flaps 45 to effect the dispensing of the finely divided material. Thus, if there is no carton available to form a seal, even though the filler 27 is actuated, there will be no dispensing of the product. Accordingly, the filler 27 has an automatic no-carton nodispensing feature.

Reference is now made to FIG. 5 wherein there is illustrated a modified form of filling apparatus, which apparatus is generally identified by the numeral 125. The filling apparatus includes a shroud 126 which is identical with the shroud 26 and will not be described in more detail hereinafter. The apparatus 125 also includes a filler 127 which is of the same general type as the filler 27, but of a slightly different configuration.

The filler 127 includes a magazine 128 which includes an outer shell 129 and an inner liner 130. The opposite ends of the shell 129 and the liner 130 will be secured together in sealed relation with the lower ends being secured together by a supporting member 132 in the form of a ring. It is to be understood that the magazine 128 differs from the magazine 28 primarily in that it is preferred the magazine 128 be of a rectangular cross section although it could be of a circular cross section if it is so desired.

The filler 127 also includes a housing 133 which is releaseably secured to the supporting member 132 by means of suitable fasteners 134. The housing 133 includes a depending outer wall 135 and a depending inner wall 136 which combine to define a chamber or compartment 137. The inner wall 136 also defines an inner chamber 138.

A valve member 140 is seated within the housing 133 and includes an upper flange 141 which is automatically clamped to the supporting member 132 in sealed relation when the housing 133 is in position. The valve member 140 also includes a lower flange 142 which is clamped against the lower end of the wall 136 in sealed engagement by means of a clamping ring 143 which is secured in place by means of fasteners 144.

The inner surface of the wall 136 is provided with an annular recess 146 opening into the space between the valve member 140 and the wall 136. A port 147 formed in the housing 133 communicates with the recess 146 and has coupled thereto a fluid line 148.

The lower end of the chamber 137 is closed by a filter member 149 which has an inner portion clamped to the wall 136 by the clamp ring or plate 143. The outer portion of the filter member 149 is clamped to the lower end of the wall 135 by means of an adapter plate 150.

It is to be understood that there are two material differences between the filler 1217 and the filler 2'7. First, the valve member 1411) is rectangular in cross section as opposed to being circular in cross section. Secondly, the valve member 140 is not provided with the equivalent of the flap 15 although it is feasible to provide such flaps. Secondly, it is to be noted that the wall 136 projects materially below the wall 135 and the filter member 1 19 has a substantial vertical component. In some instances it may be desirable to utilize valve member 140 as opposed to the valve member Ml. n the other hand, the downward projection of the wall 136 below the wall 135 has numerous advantages. In the first place, when desired, the filler 127 may project further down into the carton so as to control the available volume of the carton 15 whereby when initially filled, the carton 15 will not be filled to the top, but will have a definite air space in the upper part thereof. However, since the finely divided material is highly compacted, when the finely divided material is agitated, such as during handling of the package, the air will be mixed within the finely divided material and when the package reaches the ultimate purchaser, it will again be filled to the top.

A further advantage of the specific housing and filter con figuration is that initially the carton 15 may be filled to overflowing. The advantages of this arrangement are schematically illustrated in FIGS. 8 through 12.

Referring first to FIG. 8, it will be seen that inasmuch as the carton 15 has a liner 22 which extends up above the body 16 thereof and the liner 22 forms a seal in the flap area of the carton 15, it is possible to fill the carton 15 to overflowing. It will thus be seen that the material within the carton 15, which material is identified by the numeral 161i, is formed with a recess 161 therein which extends down below the fold line. At the same time, the material 160 has a portion 162 thereof disposed above the fold line 62. The extent of the recess 161 and the portion 162 depends upon the configuration of the lower part of the filler 127, including the filter member 1419.

When the carton 15 is filled in the manner illustrated in FIG. 8, it can still be closed in the normal manner. As is clearly shown in FIG. 9, the first step of closing the carton 15 consists of the inward folding of the end flaps l8 and 19. When the end flaps 18 and 19 are folded inwardly, since the material 161) is highly compacted and is substantially devoid of entrapped gases, it will merely crumble inwardly into the recess 161 as illustrated. The inward folding of the end flaps 13 and 19 also results in the inward folding of the liner 22 so that there is no escape of any of the material 160.

When the end flaps 18 and 19 are fully folded inwardly as is illustrated in FIG. 10, it will be seen that the recess 161 is substantially, if not completely, filled. It is now merely necessary to inwardly fold the side flaps 20 and 21 to complete the formation of the end closure for the carton. The folding of the side flap 20 is illustrated in FIG. 11 while the folding of the side flap 21 is illustrated in FIG. 12. It is to be noted that the side flap 21 extends above the liner 22 providing an exposed portion thereof which may be readily adhesively bonded to the side fiap 21].

It is to be understood that inasmuch as the carton 15 is completely sealed with respect to the filler at the time of the filling of the carton, the filling is a dust free operation. Secondly, since the material placed within the carton is of a uniform predetermined density, and since the carton may have the configuration and effective volume thereof controlled, the carton may be filled with a predetermined weight of material without weighing the material. It is to be further understood that since those portions of the side flaps of the carton which are adhesively bonded together never come into contact with dusty surfaces, there is no possibility of the product being placed within the carton interfering with the proper sealing thereof.

It is to be understood that variations in filter member configurations and valve member cross sections may be readily made without departing from the spirit of the invention. In addition, it is to be understood that the amount the filler is telescoped within the carton during the filling operation may be varied in accordance with the filling requirements.

Although only preferred embodiments of the filling apparatus and method of utilizing the same have been specifically illustrated and described, it is to be understood that minor variations may be made therein without departing from the spirit of the invention.

I claim:

1. An apparatus for filling a flexible container with compacted finely divided material, said apparatus comprising a shroud for receiving a container and a filler of the pressure differential type, said shroud including sealing means for sealing engagement with the exterior of a container and pneumatically supporting a container during the filling thereof to establish and maintain a predetermined shape of the container and the volume thereof, said filler including a housing having a portion thereof receivable in a container, and said housing portion having sealing means for sealing engagement with the interior of a container, said filler including a pneumatically operated valve member requiring a seal between said housing portion and a container for the opening of said valve member whereby said filler is of the no-container no-dispensing type, said pneumatically operated valve member being in the form of a plurality of resilient flaps normally preventing material flow through said filler and movable to flow permitting positions in response to the drawing of a. vacuum through said housing and in a container being filled.

2. The apparatus of claim 1 wherein said apparatus is particularly adapted for filling a container in the form of a carton of a rectangular section, and said shroud being split diagonally of the intended carton.

3. The apparatus of claim 1 wherein said shroud has an interior wall configuration for providing overall contact with a container while still providing for a minimal contact with a container.

1. The apparatus of claim 1 wherein said apparatus is particularly adapted for filling a container in the form of a carton having a body, upstanding closure flaps and a liner and wherein a seal may be formed with the liner above the body, and wherein said filler is proportioned to position said sealing means thereof above the carton body whereby a carton may be filled to overflowing with a cavity left in the material disposed in the body due to the filler and wherein the overflowing material may be displaced into the cavity during the folding of the carton closure flaps to seal the carton.

5. An apparatus for filling a flexible container with compactly finely divided material, said apparatus comprising a shroud for receiving a container and a filler of the pressure differential type, said shroud including sealing means for sealing engagement with the exterior of a container and pneumatically supporting a container during the filling thereof to establish and maintain a predetermined shape of the container and the volume thereof, said filler including a housing having a portion thereof receivable in a container, and said housing portion having sealing means for sealing engagement with the interior of a container, said filler including a pneumatically operated valve member requiring a seal between said housing portion and a container for the opening of said valve member whereby said filler is of the no-container no-dispensing type, said apparatus being particularly adaptable for filling a container in the form of a carton of a rectangular section and having a body, upstanding closure flaps and a liner wherein a seal may be formed with the liner above the body, said filler being proportioned to position said sealing means thereof above the carton body whereby a carton may be filled to overflowing with a cavity left in the material disposed in the body due to the filler and wherein the overflowing material may be displaced into the cavity during the folding of the flaps to seal the carton, and said shroud is split diagonally of the intended carton. 

1. An apparatus for filling a flexible container with compacted finely divided material, said apparatus comprising a shroud for receiving a container and a filler of the pressure differential type, said shroud including sealing means for sealing engagement with the exterior of a container and pneumatically supporting a container during the filling thereof to establish and maintain a predetermined shape of the container and the volume thereof, said filler including a housing having a portion thereof receivable in a coNtainer, and said housing portion having sealing means for sealing engagement with the interior of a container, said filler including a pneumatically operated valve member requiring a seal between said housing portion and a container for the opening of said valve member whereby said filler is of the no-container nodispensing type, said pneumatically operated valve member being in the form of a plurality of resilient flaps normally preventing material flow through said filler and movable to flow permitting positions in response to the drawing of a vacuum through said housing and in a container being filled.
 2. The apparatus of claim 1 wherein said apparatus is particularly adapted for filling a container in the form of a carton of a rectangular section, and said shroud being split diagonally of the intended carton.
 3. The apparatus of claim 1 wherein said shroud has an interior wall configuration for providing overall contact with a container while still providing for a minimal contact with a container.
 4. The apparatus of claim 1 wherein said apparatus is particularly adapted for filling a container in the form of a carton having a body, upstanding closure flaps and a liner and wherein a seal may be formed with the liner above the body, and wherein said filler is proportioned to position said sealing means thereof above the carton body whereby a carton may be filled to overflowing with a cavity left in the material disposed in the body due to the filler and wherein the overflowing material may be displaced into the cavity during the folding of the carton closure flaps to seal the carton.
 5. An apparatus for filling a flexible container with compactly finely divided material, said apparatus comprising a shroud for receiving a container and a filler of the pressure differential type, said shroud including sealing means for sealing engagement with the exterior of a container and pneumatically supporting a container during the filling thereof to establish and maintain a predetermined shape of the container and the volume thereof, said filler including a housing having a portion thereof receivable in a container, and said housing portion having sealing means for sealing engagement with the interior of a container, said filler including a pneumatically operated valve member requiring a seal between said housing portion and a container for the opening of said valve member whereby said filler is of the no-container no-dispensing type, said apparatus being particularly adaptable for filling a container in the form of a carton of a rectangular section and having a body, upstanding closure flaps and a liner wherein a seal may be formed with the liner above the body, said filler being proportioned to position said sealing means thereof above the carton body whereby a carton may be filled to overflowing with a cavity left in the material disposed in the body due to the filler and wherein the overflowing material may be displaced into the cavity during the folding of the flaps to seal the carton, and said shroud is split diagonally of the intended carton. 